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| Voters: 36. You may not vote on this poll | |||
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#1
03-01-2013, 10:23 AM
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Manual transmission 240D Shifter Assembly rebuild?
I am preparing to rebuild - refresh my 1980 240D manual transmission (floor) Shift lever Assembly.
The floor shift lever is slopping around = difficult going from 2-3 over to 3-4. .
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ 
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#2
03-01-2013, 01:31 PM
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I rebuilt mine when I put the 617 into my 240D. I found it quit easy using only a couple new internal parts. The problem I found before I drove the car was that the plastic body that contains this line up of parts had been pretty badly damaged from underneath the car. It probably still shifted. But I used this diagram of the parts to reassemble it and it went well and easy. Then I made the 6mm key to properly adjust the rods by cutting the head off a long 6mm bolt, then cut the threaded part from the un-threaded part, then welded them together at 90 degrees. I also did grind just a little point to the un-threaded end to get it to slide in a little easier.
http://mb.ilcats.ru/part/class/1/ccode/F/cat/68K/type/123/subtype/123/group/26
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Junqueyardjim Christianity, if false, is of no importance, and if true, of infinite importance. The only thing it cannot be is moderately important. C.S. Lewis 1983 Mercedes W123 240D 4 Speed 285,000 on the road with a 617 turbo, beautiful butter yellow, license plate # 83 240D INDIANA 2003 Jaguar Type X, AWD. beautiful, good mileage, Mom's car, but I won't let her drive it!
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#3
03-01-2013, 05:34 PM
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OK
The parts arrived.
I will try to get this done in the next week. .
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/
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#5
04-14-2013, 08:29 PM
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OK
Quote:
The failure was sudden, no time for video. As a momentary solution, I am posting cell phone pictures of what I encountered. FYI: The second gear synchromesh must be replaced soon, and I will see about doing this shift lever video then. .
__________________
ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/
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#6
04-14-2013, 08:30 PM
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I pinched the rubber boot with my fingers, and pulled the bottom loose.
       
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 05-12-2013 at 11:59 AM.
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#7
04-14-2013, 08:30 PM
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 04-14-2013 at 08:52 PM.
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#8
04-14-2013, 08:30 PM
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 04-14-2013 at 10:31 PM.
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#9
04-14-2013, 08:30 PM
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 04-14-2013 at 10:28 PM.
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#10
04-14-2013, 08:30 PM
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 04-14-2013 at 10:24 PM.
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#11
04-14-2013, 08:31 PM
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    .
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 04-14-2013 at 10:31 PM.
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#12
04-14-2013, 09:06 PM
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Do I need my Captin Midnight Super Decoder Ring to decode these last 5 Posts?
 Charlie
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there were three HP ratings on the OM616... 1) Not much power 2) Even less power 3) Not nearly enough power!! 240D w/auto Anyone that thinks a 240D is slow drives too fast. 80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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#13
04-14-2013, 10:29 PM
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Chuckle
Quote:
 It takes a few minutes to add the picture links. .
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ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/
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#14
04-14-2013, 10:45 PM
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Ok, understand.
Forgot where I put my ring anyway. I took one of these apart several years ago to clean out the old grease and crap spilt on it from the top, and them re-lube it. the most difficult part, as I remember, was getting those 2 springy washers back in, and it all back together. I bought one of those shift boots to replace the original one that was is really bad shape. the new one was made in India, and is the stiffest piece of plastic &^%$. when it is cold, it makes it hard to shift, and the thing won`t stay under the groove on the shifter plate. I found a leather one off a 96 Saab a few days ago, Iam going to retrofit. I have a spare black plastic shifter plate from PNP I will use. Charlie
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there were three HP ratings on the OM616... 1) Not much power 2) Even less power 3) Not nearly enough power!! 240D w/auto Anyone that thinks a 240D is slow drives too fast. 80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works
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#15
04-15-2013, 05:19 AM
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Yep
Quote:
The new shift boot is Mercedes STAR marked, much more flexible. .
__________________
ASE Master Mechanic asemastermechanic@juno.com Prototype R&D/testing: Thermal & Aerodynamic System Engineering (TASE) Senior vehicle instrumentation technician. Noise Vibration and Harshness (NVH). Dynamometer. Heat exchanger durability. HV-A/C Climate Control. Vehicle build. Fleet Durability Technical Quality Auditor. Automotive Technical Writer 1985 300SD 1983 300D 1984 190D 2003 Volvo V70 2002 Honda Civic https://www.boldegoist.com/ Last edited by whunter; 05-12-2013 at 12:02 PM.
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